Auto hobbyists and handypersons sometimes have the need to cut aluminum sheeting, and don't always have the luxury of going to a metalworking shop to take care of it. Storm doors usually have windows so that you can still see outside after opening the main door. For cutting thicker sections I'll use Walter cool cut. Even the most energy-efficient HVAC systems boasting all the latest technology can still cost you plenty if that conditioned air is wasted through leaky doors, windows or walls. When we moved in, the front door wouldn't open all the way; it drug the floor at about 70 degrees from full open. Set the depth of your Dremel Ultra-Saw. If necessary, cut again from the other side of the door to straighten that edge. Make sure that the top to be cut … (Makita for the most part) For trimming, shaving and cutting thinner sheet I just run the blade dry, it's easier and less to clean up. Consider the type of cut you'll be making, such as a cut-out or a cut-through. Metal siding covers the surface of many homes and outbuildings. Recruit an assistant to hold the door when removing the door hinge pins. Transition strips come in various sizes and materials, with one of those materials being metal. Pry the hinge pins out of the hinges with a screwdriver, then pull the door off the hinges and lay it down on a pair of saw horses or a table. Determine exactly where the cut should be made if you intend to make a precise cut on either side of the marked line. Begin in one corner and continue around the form. If it it a heavy steel door, get a partner to help with this job. Crimp the ends of the groove closed with pliers to hold the sweep permanently in place. They don't use aluminum for entry doors because it's too soft. Consider the type of cut you'll be making, such as a cut-out or a cut-through. Remove any door hardware. How to Use a Jigsaw to Cut Through An Aluminum Door Install a metal cutting blade into a jigsaw. Make precise cutting marks on the door. For clean, precise holes in thin sheet metal, make a wood sandwich. Steel used for a door is the same as steel used in any other application. Your best bet is to use a jigsaw with a fine metal blade. Hinges are small, metal plates that allow doors to open and close. A metal door sweep will need to be cut with a hacksaw. Tips. It would be very difficult, if not impossible. Put a metal cutting blade on your jigsaw to cut the outline. The wooden ‘bread’ layers of the sandwich keep the sheet metal flat and prevent the drill bit from wandering as it bores through the sheet metal. Extend blade life by keeping the saw’s speed slow. A storm door is a secondary door located outside the main exterior door. Installing the dog door frame will also be slightly different with a storm door. Aluminum Door Frame Profile, Cut-To-Size - order from the Häfele America Shop. How to Cut a Door Threshold - PDF. Trim off its overhanging end with a utility knife. Cutting a metal transition strip only requires a few tools to complete. It provides additional protection in the event of bad weather. Aluminum sheet metal can be cut with a variety of methods ranging from manual tools to highly advanced industrial systems.